Dreaded crossmember

Well after doing a full brake system O/H calipers and braided hoses great - while working I noticed the rear crossmember is shot also a few holes in the chassis.

1. Cross member has anyone made there own? I measured and cant see how a box section 50mm x 90mm would not work and be even stronger? any thoughts

2. Chassis repair whats best to do? I see yrm do chassis repair sections but the holes are on a curve section. How is best to sort that?

this is mine

dead easy to do but i would say something a bit wider than 90mm would be the way forward but have a look.


HTH

That look great mate, Iv got another plan after looking at yours to get round the broader support. Ill have a look again today and see if its possible and write back. Well done doing it yourself like you say better thank paying 200+ for a thin replacement

DiscoPol said:

this is mine

dead easy to do but i would say something a bit wider than 90mm would be the way forward but have a look.


HTH

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Hi HTH, you are really doing some great work on your Disco, with the rear cross-member and sills - I just can't help wondering how much she weighs now?

thebiglad said:

Hi HTH, you are really doing some great work on your Disco, with the rear cross-member and sills - I just can't help wondering how much she weighs now?

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It's all balanced out with the lack of interior and no back seats,I would bet she is lighter than stock even with the winch and hd bumpers.
on a 1200km run last weekend she returned a very respectable 28.8mpg over 3 days and 150km was done off road. there are no door panels in the rear or any form of unnecessary trim back there no back seats no carpets or sound proofing mats throughout and the standard front disco seats have been replaced with lightweight Smartcar seats, as i say im willing to bet she is either the same or lighter than the standard 300 tdi.